Substrate processing apparatus having exhaust gas decomposer, and exhaust gas processing method therefor

ABSTRACT

Disclosed is a substrate processing apparatus and the method of processing an exhaust gas. The substrate processing apparatus and the method of processing an exhaust gas according to the present invention, an exhaust gas decomposition module may decompose a source gas exhausted from a process chamber to decompose a ligand of the source gas. Also, the ligand and the source gas of which the ligand has been decomposed may be put in a stabilized state by reacting with separately supplied O2, N2O, or O3, and then, may be changed to a mixed gas including a reactant gas mixed therewith. Subsequently, the mixed gas may flow into the exhaust pump and may be emitted. Alternatively, the ligand and the source gas may be mixed with the reactant gas and may be emitted. Therefore, the ligand and the source gas of which the ligand has been decomposed may not react with the reactant gas or heat which occurs in the exhaust pump, and thus, the ligand-decomposed source gas and the ligand flowing into the exhaust pump are not deposited on an inner surface of the exhaust pump. Also, the ligand-decomposed source gas and ligands piled in the exhaust pump are not exploded.

CROSS-REFERENCE TO RELATED APPLICATION

This U.S. non-provisional patent application is a divisional of U.S. patent application Ser. No. 15/766,000, filed on 4 Apr. 2018, Publication No. US 2018/0305815 A1, which claims priority under 35 U.S.C. § 371 to International Patent Application No. PCT/KR2016/011045, filed on Oct. 4, 2016, and to 35 U.S.C. § 119 to Korean Patent Application No. 10-2015-0139794, filed on Oct. 5, 2015, in the Korean Intellectual Property Office, the contents of both which are herein incorporated by reference in their entireties.

TECHNICAL FIELD

The present invention relates to a substrate processing apparatus having exhaust gas decomposer and an exhaust gas processing method therefor, which decompose a source gas emitted from a process chamber to prevent an exhaust pump from being damaged by an exhaust gas.

DESCRIPTION OF THE RELATED ART

Semiconductor devices, flat panel display devices, or solar cells are manufactured by a thin film deposition process of depositing a source material on a substrate such as a silicon wafer or glass, a photolithography process of exposing or covering a selected area in thin films which are deposited by using a photosensitive material, and an etching process of removing a thin film in a selected area to perform desired patterning.

Examples of the thin film deposition process include a physical vapor deposition (PVD) process, a chemical vapor deposition (CVD) process, and an atomic layer deposition (ALD) process.

The thin film deposition process deposits a thin film on a substrate by using various materials. In this case, only the small amount of a source gas which is a precursor flowing into a process chamber including a space for processing a substrate is used in a deposition process, and most of the source gas is emitted to outside the process chamber along with a byproduct which occurs in the deposition process.

A source gas and a byproduct of the process chamber which are not used in the deposition process are emitted to outside the process chamber by an exhaust line and an exhaust pump. That is, the source gas and the byproduct of the process chamber which are not used in the deposition process are extracted by the exhaust pump and are emitted to outside the exhaust pump through the exhaust line and the exhaust pump.

Moreover, the source gas which is not used in the deposition process is decomposed by reacting with heat occurring in the exhaust pump and a reactant gas emitted from the process chamber, and the decomposed source gas is deposited on an inner surface of the exhaust pump to form a thin film. In this case, clearance between elements configuring the exhaust pump is changed, and for this reason, the exhaust pump is damaged.

When a source gas which is for a low temperature and is emitted to outside the process chamber is piled in the exhaust pump, the source gas can be exploded by heat which occurs in the exhaust pump.

SUMMARY

An aspect of the present invention is directed to provide a substrate processing apparatus having exhaust gas decomposer and an exhaust gas processing method therefor, which solve all of the above-described problems of the related art.

Another aspect of the present invention is directed to provide a substrate processing apparatus having exhaust gas decomposer and an exhaust gas processing method therefor, which decompose a source gas which is emitted from a process chamber and is not used in a deposition process, and emit the decomposed source gas through an exhaust pump, thereby preventing the exhaust pump from being damaged by the source gas and perfectly preventing the source gas from being exploded.

Technical Solution

A substrate processing apparatus including: a process chamber including a space where a substrate is processed; a substrate supporting means installed in the process chamber, the substrate being disposed on the substrate supporting means; a source gas distribution means distributing a source gas to the substrate; a reactant gas distribution means distributing a reactant gas to the substrate; a source gas exhaust line guiding the source gas of the process chamber to be emitted to outside the process chamber; a reactant gas exhaust line guiding the reactant gas of the process chamber to be emitted to outside the process chamber; an exhaust pump communicating with each of the source gas exhaust line and the reactant gas exhaust line to respectively exhaust the source gas and the reactant gas to the source gas exhaust line and the reactant gas exhaust line; and an exhaust gas decomposition module installed in the source gas exhaust line between the process chamber and the exhaust pump to decompose the source gas which flows into the exhaust pump through the source gas exhaust line.

In another aspect of the present invention, there is provided an exhaust gas processing method of a substrate processing apparatus, exhausting and processing a source gas and a reactant gas, which are not used in a deposition process, in a source gas and a reactant gas which are distributed to a process chamber where a substrate is processed and deposit a thin film on the substrate, including: respectively exhausting a source gas and a reactant gas to a source gas exhaust line and a reactant gas exhaust line by using an exhaust pump, one side of the source gas exhaust line communicating with the process chamber, the other side of the source gas exhaust line communicating with the exhaust pump, one side of the reactant gas exhaust line communicating with the process chamber, the other side of the reactant gas exhaust line communicating with the exhaust pump; decomposing the source gas flowing into the source gas exhaust line; and emitting a mixed gas, which is generated by mixing the decomposed source gas of the source gas exhaust line with the reactant gas of the reactant gas exhaust line, through the inside of the exhaust pump.

Advantageous Effects

In the substrate processing apparatus and the method of processing an exhaust gas according to an embodiment of the present invention, the exhaust gas decomposition module may decompose a source gas exhausted from the process chamber to decompose a ligand of the source gas. Also, the ligand and the source gas of which the ligand has been decomposed may be put in a stabilized state by reacting with separately supplied O₂, N₂O, or O₃, and then, may be changed to a mixed gas including a reactant gas mixed therewith. Subsequently, the mixed gas may flow into the exhaust pump and may be emitted. Alternatively, the ligand and the source gas may be mixed with the reactant gas and may be emitted. Therefore, the ligand and the source gas of which the ligand has been decomposed may not react with the reactant gas or heat which occurs in the exhaust pump, and thus, the ligand-decomposed source gas and the ligand flowing into the exhaust pump are not deposited on an inner surface of the exhaust pump. Also, the ligand-decomposed source gas and ligands piled in the exhaust pump are not exploded.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view illustrating a configuration of a substrate processing apparatus according to an embodiment of the present invention.

FIG. 2 is a plan cross-sectional view of FIG. 1.

FIG. 3 is a schematic view illustrating a configuration of a substrate processing apparatus according to another embodiment of the present invention.

FIG. 4 is a flowchart illustrating an exhaust gas processing method of a substrate processing apparatus according to an embodiment of the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to the exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

In the specification, in adding reference numerals for elements in each drawing, it should be noted that like reference numerals already used to denote like elements in other drawings are used for elements wherever possible.

The terms described in the specification should be understood as follows.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “first” and “second” are for differentiating one element from the other element, and these elements should not be limited by these terms.

It will be further understood that the terms “comprises”, “comprising,”, “has”, “having”, “includes” and/or “including”, when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The term “at least one” should be understood as including any and all combinations of one or more of the associated listed items. For example, the meaning of “at least one of a first item, a second item, and a third item” denotes the combination of all items proposed from two or more of the first item, the second item, and the third item as well as the first item, the second item, or the third item.

The term “and/or” should be understood as including any and all combinations of one or more of the associated listed items. For example, the meaning of “a first item, a second item, and/or a third item” denotes the combination of all items proposed from two or more of the first item, the second item, and the third item as well as the first item, the second item, or the third item.

It will also be understood that when an element is referred to as being ‘on’ another element, it can be directly on the other element, or intervening elements may also be present. Further, it will be understood that when an element is referred to as being ‘under’ another element, it can be directly under, and one or more intervening elements may also be present. In addition, it will also be understood that when an element is referred to as being ‘between’ two elements, it can be the only element between the two elements, or one or more intervening elements may also be present. Other terms for describing a relationship between elements, for example, “between” and “directly between” may be understood likewise.

In each of steps, reference numerals (for example, S100, S110, S120, etc.) are used for convenience of description, and do not define the order of the steps. Also, the steps may be performed in order different from a described order unless a specific order is clearly described contextually. That is, the steps may be performed in the described order, may be simultaneously performed, or may be performed in reverse order.

Hereinafter, a substrate processing apparatus having exhaust gas decomposer and an exhaust gas processing method therefor according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

First, a substrate processing apparatus according to an embodiment of the present invention will be described.

FIG. 1 is a diagram illustrating a schematic configuration of a substrate processing apparatus according to an embodiment of the present invention, and FIG. 2 is a plan cross-sectional view of FIG. 1.

As illustrated, the substrate processing apparatus according to an embodiment of the present invention may include a process chamber 110 including a space into which a substrate 50 such as a silicon wafer, glass, or the like is loaded and processed. The process chamber 110 may include a body 111, which includes an opened top and is disposed on a relatively lower side, and a lid 115 which is coupled to the opened top of the body 111 and is disposed on a relatively upper side.

A substrate supporting means 120 on which the substrate 50 is mounted and supported may be installed on an inner lower surface of the process chamber 110.

The substrate supporting means 120 may include a supporter 121, which is disposed in the process chamber 110 and includes a top on which the substrate 50 is mounted and supported, and a supporting shaft 125 which includes an upper end coupled to a bottom of the supporter 121 and a lower end exposed to the outside of a bottom of the process chamber 110 and connected to a driving part 130.

The substrate 50 may be provided in plurality. The plurality of substrates 50 may be radially mounted and supported on the supporter 121 with respect to a center of the supporter 121. The driving part 130 may raise, lower, or rotate the substrate supporting means 120. That is, the driving part 130 may raise, lower, or rotate the supporter 121 by raising, lowering, or rotating the supporting shaft 125. Therefore, the substrate 50 mounted and supported on the supporter 121 may be raised, lowered, or rotated.

A heating unit (not shown) such as a heater or the like for heating the substrate 50 may be installed near the supporter 121 on which the substrate 50 is mounted and supported.

In order to deposit a thin film on the substrate 50, a source gas which is a material deposited on the substrate 50 and a reactant gas which helps the source gas to be easily deposited on the substrate 50 may be supplied to the process chamber 110. To this end, a source gas distribution means 141 for distributing a source gas to the substrate 50 mounted on the supporter 121 and a reactant gas distribution means 145 for distributing the reactant gas to the substrate 50 may be installed on an inner upper surface of the process chamber 110.

The source gas distribution means 141 and the reactant gas distribution means 145 may each be provided as a shower head and may be mutually divided and installed. Also, the source gas distributed from the source gas distribution means 141 may be distributed to only a source gas area 121 a opposite to the source gas distribution means 141, and the reactant gas distributed from the reactant gas distribution means 145 may be distributed to only a reactant gas area 121 b opposite to the reactant gas distribution means 145. In this case, the source gas distributed from the source gas distribution means 141 and the reactant gas distributed from the reactant gas distribution means 145 may be distributed without being mixed with each other in the middle of being distributed to the substrate 50.

Therefore, as the substrate supporting means 120 rotates, the plurality of substrates 50 mounted and supported on the substrate supporting means 120 may be sequentially located in the source gas area 121 a and may be sequentially located in the reactant gas area 121 b. That is, when the substrate 50 which is located in the source gas area 121 a and is supplied with the source gas is located in the reactant gas area 121 b and is supplied with the reactant gas according to a rotation of the substrate supporting means 120, the source gas may be deposited on the substrate 50 by reaction between the source gas and the reactant gas.

Only the small amount of each of the source gas and the reactant gas supplied to the process chamber 110 may be used in a deposition process, and most of each of the source gas and the reactant gas may be emitted to outside the process chamber 110 along with a byproduct which occurs in the deposition process

A source gas exhaust line 151, a reactant gas exhaust line 153, and an exhaust pump 155 may be provided for emitting the source gas and the reactant gas, which are not used in the deposition process, to outside the process chamber 110 along with the byproduct.

One end of the source gas exhaust line 151 may communicate with a bottom of the process chamber 110, and the other end of the source gas exhaust line 151 may communicate with the exhaust pump 155. One end of the reactant gas exhaust line 153 may communicate with the bottom of the process chamber 110, and the other end of the reactant gas exhaust line 153 may communicate with the exhaust pump 155. In this case, the one end of the source gas exhaust line 151 and the one end of the reactant gas exhaust line 153 may each communicate with the bottom of the process chamber 110 disposed just under the source gas area 121 a and the reactant gas area 121 b.

Therefore, when the exhaust pump 155 provided as a vacuum pump or the like is driven, a source gas which is distributed to the source gas area 121 a but is not used in the deposition process may be extracted and may flow into the source gas exhaust line 151, and a reactant gas which is distributed to the reactant gas area 121 b but is not used in the deposition process may be extracted and may flow into the reactant gas exhaust line 153. Subsequently, the source gas and the reactant gas may be changed to a mixed gas and may flow into the exhaust pump 155, and the mixed gas may be emitted to outside the exhaust pump 155 through the inside of the exhaust pump 155.

A source gas which is not used in the deposition process and flows into the exhaust pump 155 through the exhaust line 151 may react with heat occurring in the exhaust pump 155 or a reactant gas which flows into the exhaust pump 155 through the reactant gas exhaust line 153, and may be deposited on an inner surface of the exhaust pump 155. For this reason, the exhaust pump 155 can be damaged. Particularly, when a source gas is for a low temperature, a source gas piled in the exhaust pump 155 can be exploded by heat which occurs in the exhaust pump 155.

In order to prevent such problems, the substrate processing apparatus according to an embodiment of the present invention may include an exhaust gas decomposition module 160 which decomposes a source gas flowing into the source gas exhaust line 151.

The exhaust gas decomposition module 160 may be installed near the source gas exhaust line 151 between the process chamber 110 and the exhaust pump 155 and may decompose the source gas flowing into the source gas exhaust line 151. In this case, the exhaust gas decomposition module 160 may decompose a ligand of the source gas, and the ligand-decomposed source gas may be supplied to the exhaust pump 155.

Since the ligand and the ligand-decomposed source gas are in an unstable state, it is required to stabilize the ligand and the ligand-decomposed source gas. To this end, O₂, N₂O, or O₃ may be supplied to source gas exhaust line 151 between the exhaust gas decomposition module 160 and the exhaust pump 155. Therefore, the ligand and the ligand-decomposition module source gas may be put in a stabilized state by reacting with O₂, N₂O, or O₃.

Subsequently, the ligand and the ligand-decomposed source gas may be changed to a mixed gas including a reactant gas of the reactant gas exhaust line 153 mixed therewith. Therefore, the ligand and the ligand-decomposed source gas may not react with the reactant gas or heat which occurs in the exhaust pump 155, and thus, the ligand-decomposed source gas and the ligand flowing into the exhaust pump 155 are not deposited on an inner surface of the exhaust pump 155. Also, the ligand-decomposed source gas and ligands piled in the exhaust pump 155 are not exploded.

In this case, the exhaust gas decomposition module 160 may be provided as a plasma generator, which generates plasma to decompose a source gas, or a heat source which heats and decomposes the source gas.

FIG. 3 is a diagram illustrating a schematic configuration of a substrate processing apparatus according to another embodiment of the present invention. Only a difference between FIG. 3 and FIG. 1 will be described below.

As illustrated, in the substrate processing apparatus according to another embodiment of the present invention, a ligand of a source gas exhaust line 251 decomposed by an exhaust gas decomposition module 260, a ligand-decomposed source gas, and a reactant gas of a reactant gas exhaust line 252 may flow into an exhaust pump 255, and then, may be mixed with each other in the exhaust pump 255. Subsequently, the mixed gas may be emitted to outside the exhaust pump 255.

Hereinafter, an exhaust gas processing method of a substrate processing apparatus according to the present embodiment will be described with reference to FIGS. 1 to 4. FIG. 4 is a flowchart illustrating an exhaust gas processing method of a substrate processing apparatus according to an embodiment of the present invention.

As illustrated, a source gas and a reactant gas, which is not used in the deposition process of depositing a thin film on the substrate 50, in a source gas and a reactant gas distributed to the process chamber 110 may be respectively supplied to the source gas exhaust line 151 and the reactant gas exhaust line 153 and may be emitted to outside the process chamber 110 in step S110.

As described above, one side of the source gas exhaust line 151 may communicate with the process chamber 110, and the other side may communicate with the exhaust pump 155. Also, one side of the reactant gas exhaust line 153 may communicate with the process chamber 110, and the other side may communicate with the exhaust pump 155. Therefore, when the exhaust pump 155 is driven, the source gas and the reactant gas of the process chamber 110 may be respectively extracted and exhausted to the source gas exhaust line 151 and the reactant gas exhaust line 153.

Subsequently, in step S120, the source gas flowing into the source gas exhaust line 151 may be decomposed by the exhaust gas decomposition module 160. Also, in step S130, the decomposed source gas of the source gas exhaust line 151 and the reactant gas of the reactant gas exhaust line 153 may be changed to a mixed gas through mixing. Subsequently, in step S140, the mixed gas may be emitted to the outside through the inside of the exhaust pump 155.

In this case, the exhaust gas decomposition module 160 may be a plasma generator which generates plasma to decompose a source gas, or may be a heat source which heats and decomposes the source gas. Also, a ligand may be separated from the source gas of the source gas exhaust line 151.

As described above, the ligand and the ligand-decomposed source gas may be put in a stabilized state by reacting with separately supplied O₂, N₂O, or O₃, may be mixed with the reactant gas of the exhaust pump 155, may flow into the exhaust pump 155, and may be emitted. Alternatively, the ligand and the source gas may be mixed with the reactant gas of the reactant gas exhaust line 153 in the exhaust pump 155 and may be emitted.

In the substrate processing apparatus and the method of processing an exhaust gas according to the present embodiment, the exhaust gas decomposition module 160 (260) may decompose a ligand of a source gas. Subsequently, the ligand, the ligand-decomposed source gas, and a reactant gas of the reactant gas exhaust line 153 (253) which have been stabilized may be changed to a mixed gas. The mixed gas may flow into the exhaust pump 155 (255) and may be emitted, or the ligand and the ligand-decomposed source gas may be mixed with the reactant gas in the exhaust pump 155 (255) and may be emitted. Therefore, the ligand and the ligand-decomposed source gas may not react with the reactant gas or heat which occurs in the exhaust pump 155 (255), and thus, the ligand-decomposed source gas and the ligand flowing into the exhaust pump 155 (255) are not deposited on an inner surface of the exhaust pump 155 (255). Also, the ligand-decomposed source gas and ligands piled in the exhaust pump 155 (255) are not exploded.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. 

What is claimed is:
 1. An exhaust gas processing method of a substrate processing apparatus, exhausting and processing a source gas and a reactant gas, which are not used in a deposition process, in a source gas and a reactant gas which are distributed to a process chamber where a thin film is deposited on a substrate, the exhaust gas processing method comprising: respectively exhausting a source gas and a reactant gas to a source gas exhaust line and a reactant gas exhaust line by using an exhaust pump, one side of the source gas exhaust line communicating with the process chamber, the other side of the source gas exhaust line communicating with the exhaust pump, one side of the reactant gas exhaust line communicating with the process chamber, the other side of the reactant gas exhaust line communicating with the exhaust pump; decomposing the source gas flowing into the source gas exhaust line; and emitting a mixed gas, which is generated by mixing the decomposed source gas of the source gas exhaust line with the reactant gas of the reactant gas exhaust line, through the inside of the exhaust pump.
 2. The exhaust gas processing method of claim 1, wherein the source gas of the source gas exhaust line is decomposed by plasma generated by a plasma generator, or is decomposed through heating.
 3. The exhaust gas processing method of claim 2, wherein a ligand of the source gas of the source gas exhaust line is decomposed.
 4. The exhaust gas processing method of claim 3, wherein the ligand and the ligand-decomposed source gas of the source gas exhaust line are stabilized by reacting with one material selected from among O₂, N₂O, and O₃ supplied to the source gas exhaust line and flow into the exhaust pump.
 5. The exhaust gas processing method of claim 1, wherein the decomposed source gas of the source gas exhaust line and the reactant gas of the reactant gas exhaust line are mixed with each other and flow into the exhaust pump.
 6. The exhaust gas processing method of claim 1, wherein the decomposed source gas of the source gas exhaust line and the reactant gas of the reactant gas exhaust line are mixed with each other in the exhaust pump.
 7. The exhaust gas processing method of claim 1, wherein one end of the source gas exhaust line communicates with a source gas area disposed in the process chamber, and the other end of the source gas exhaust line communicates with the exhaust pump, wherein one end of the reactant gas exhaust line communicates with a reactant gas area disposed in the process chamber, and the other end of the reactant gas exhaust line communicates with the exhaust pump, wherein an exhaust trap is installed in the source gas exhaust line between the one end of the source gas exhaust line and the other end of the source gas exhaust line, wherein the source gas decomposed by the exhaust trap is mixed with the reactant gas to generate the mixed gas.
 8. An exhaust gas processing method of a substrate processing apparatus, exhausting and processing a source gas and a reactant gas, which are not used in a deposition process, in a source gas and a reactant gas which are distributed to a process chamber where a thin film is deposited on a substrate, the exhaust gas processing method comprising: respectively exhausting a source gas and a reactant gas to a source gas exhaust line and a reactant gas exhaust line by using an exhaust pump, one side of the source gas exhaust line communicating with the process chamber, the other side of the source gas exhaust line communicating with the exhaust pump, one side of the reactant gas exhaust line communicating with the process chamber, the other side of the reactant gas exhaust line communicating with the exhaust pump; decomposing the source gas flowing into the source gas exhaust line; and emitting a mixed gas, which is generated by mixing the decomposed source gas of the source gas exhaust line with the reactant gas of the reactant gas exhaust line, through the inside of the exhaust pump; wherein one end of the source gas exhaust line communicates with a source gas area disposed in the process chamber, and the other end of the source gas exhaust line communicates with the exhaust pump, wherein one end of the reactant gas exhaust line communicates with a reactant gas area disposed in the process chamber, and the other end of the reactant gas exhaust line communicates with the exhaust pump, wherein an exhaust decomposition module is installed in the source gas exhaust line between the one end of the source gas exhaust line and the other end of the source gas exhaust line, wherein the source gas decomposed by the exhaust decomposition module is mixed with the reactant gas to generate the mixed gas.
 9. The exhaust gas processing method of claim 8, wherein the source gas of the source gas exhaust line is decomposed by plasma generated by a plasma generator, or is decomposed through heating.
 10. The exhaust gas processing method of claim 9, wherein a ligand of the source gas of the source gas exhaust line is decomposed.
 11. The exhaust gas processing method of claim 10, wherein the ligand and the ligand-decomposed source gas of the source gas exhaust line are stabilized by reacting with one material selected from among O₂, N₂O, and O₃ supplied to the source gas exhaust line and flow into the exhaust pump.
 12. The exhaust gas processing method of claim 8, wherein the decomposed source gas of the source gas exhaust line and the reactant gas of the reactant gas exhaust line are mixed with each other and flow into the exhaust pump.
 13. The exhaust gas processing method of claim 8, wherein the decomposed source gas of the source gas exhaust line and the reactant gas of the reactant gas exhaust line are mixed with each other in the exhaust pump. 